magnum intake rebuild

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orangeneon05
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magnum intake rebuild

Post by orangeneon05 » Mon Apr 09, 2012 6:05 pm

Ok I couldn't find any information on the forum about a rebuild just for the magnum intake manifold so here goes.

I recently bought a mag intake manifold and I was wondering the.following things:

1. What is a good way to clean and shine the manifold to look more polished.
2. What is the part number for the gasket between the runners and the butterfly valve housing and the manifold and the block.
3. Are the fuel injectors the same from all the models of car. And which are better for a atx magnum set up.
4. Lastly what bolts are needed for the head I've heard that the bolts on the plasic manifold are too small. And I've counted 8 bolt holes on the mag intake are all of them used or just some.
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Post by Donkeypuncher » Mon Apr 09, 2012 7:08 pm

Any good aluminum polish works well to shine it up a bit, or you could sand it down and really polish it. The injectors are all the same for 2g neons, excluding the srt.

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Post by NickKo » Mon Apr 09, 2012 7:15 pm

I thought I once read that the 2001+ Neons had revised injectors, with a slightly different flow rate ?? :-k The change had something to do with the switch to the 58PSI fuel pressure regulator, for the 2001+ model year, If I Recall Correctly.

Hopefully, one of the other knowledgeable folks ( Bill, or John ? ) can confirm this.



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-2000 Ply.LX w/MTX = Maddog STS; CAI; 2.5 exh.; 60mm T/B
-2001 ATX w/Syked PCM + Magnum header
-2001 ACR w/SRT T/B bored out to 55mm

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Post by orangeneon05 » Mon Apr 09, 2012 10:26 pm

thanks on the polish idea any clue on sand paper grits to get a good shine.
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Post by occasional demons » Mon Apr 09, 2012 10:31 pm

From what I have read '98 and up injectors are the same...

But I have also wondered about the pressure difference. Unless the PCM's are able to manage that with pulsewidths.

There should be a PN list for the Mag IM parts in the PN section.
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Post by orangeneon05 » Mon Apr 09, 2012 10:41 pm

thanks ill take a look
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Post by occasional demons » Mon Apr 09, 2012 10:48 pm

viewtopic.php?t=29860

Just in case. :lol:
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Post by orangeneon05 » Mon Apr 09, 2012 11:01 pm

that link is unclear and confusing to me.

here are a couple other links that will help for part #'s

viewtopic.php?t=51393

viewtopic.php?t=11858&highlight=gasket+part+number

viewtopic.php?p=136906#136906

any other help will be great.
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Post by Danteneon » Tue Apr 10, 2012 1:11 pm

orangeneon05 wrote:thanks on the polish idea any clue on sand paper grits to get a good shine.
To get the intake to shine, you will need to make the manifold smooth first. Start with 80 grit and work your way up to 2000. You will want to get a Dremel for grinding down the casting marks and extra flashing. After that, it's time to start polishing.

Expect to spend around 60 hours on this to make it look like mine. Most people give up long before that point though.
If I could just figure out how to meld the Outback and the Neon into one car...

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Post by orangeneon05 » Tue Apr 10, 2012 9:49 pm

ill put the time in because i plan to put it on around august. and if you dremel down the extra metal around the injectors wont that make the intake less stable. i can understand the stamping marks because the are not there for structure.

let me know what you think.
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Post by occasional demons » Tue Apr 10, 2012 10:08 pm

orangeneon05 wrote: and if you dremel down the extra metal around the injectors wont that make the intake less stable.

let me know what you think.
Do you mean the webs on the outside of the runners?

As long as you use the bottom bending strut, it should be fine. It is under $12 at the dealer if you don't have one. A few Magnum IMs have cracked recently, and the strut was not used. These were non modified also.

viewtopic.php?t=60530

Remove the zero from the beginning of the PN to be correct. Some parts ppl aren't smart enough, and will tell you it is not the correct number.
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Post by orangeneon05 » Wed Apr 11, 2012 12:00 am

yea the webs on the top of the runners. and ill look for that bracket
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Post by Danteneon » Wed Apr 11, 2012 1:19 pm

You don't need to remove all of the webbing. There is a lot of extra material that can be removed safely though.

Here are some pics I took during the grinding stage.

Image

Image

What they look like before polishing...note the excess removed near the bolt holes.

Image

It's a good idea to keep the material intact under the runners.

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What the final product can look like...

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If I could just figure out how to meld the Outback and the Neon into one car...

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Post by orangeneon05 » Wed Apr 11, 2012 1:24 pm

thanks dante thats what i was looking for that last one where you can see the top webs. i thought that was alot of structural metal to remove and be no bueno if you did remove it. do you coat it with anything after all the sanding besides polish so it wont rust or will it be rust free with out maintenance.
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Post by Danteneon » Wed Apr 11, 2012 1:45 pm

Well, it's aluminum, so no worries about rust :lol:

I did not coat it with anything. I have to keep it clean and keep it polished to maintain the finish. If it was good enough to my eyes, I would have it powdercoated clear. Alas, it isn't good enough for my OCD.
If I could just figure out how to meld the Outback and the Neon into one car...

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Post by orangeneon05 » Wed Apr 11, 2012 2:15 pm

haha and thats all the way to 2000 grit
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Post by Danteneon » Wed Apr 11, 2012 2:18 pm

Beyond actually. Once I was done with the paper, I started with rubbing compound, went to polishing compound, then finished with dry buffing. It's just that some places need more base work before I call it good.
If I could just figure out how to meld the Outback and the Neon into one car...

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Post by orangeneon05 » Wed Apr 11, 2012 2:26 pm

gotcha. so i called and got a PN for the gaskets can anyone confirm that this is two gaskets or just one.

PN=4648623AB
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Post by Danteneon » Wed Apr 11, 2012 2:35 pm

That is the part number for the gasket to the head. It is an one piece gasket, unlike the non Magnum manifold.

4648623AB gasket for the runners to the head (need 1)

4884067AB gasket that goes inbetween plenum & butterflies / runners
(need 1)
If I could just figure out how to meld the Outback and the Neon into one car...

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Post by orangeneon05 » Wed Apr 11, 2012 2:55 pm

bingo bango just what i need. time to get a shopping list together and buy parts. thanks for all our help man.

if i put a picture up of the injector gaskets is there any way you can tell if they are bad and what this part is that i dont know if i need.
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Post by occasional demons » Wed Apr 11, 2012 3:31 pm

The injector o rings are dirt cheap. May as well just put new ones on. You can get them anywhere. Tho if you can find the blue ones, they seem to be a better quality. IDK what brand they are tho. :(
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Post by orangeneon05 » Wed Apr 11, 2012 5:12 pm

what about the plastic tips after the o rings.
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Post by occasional demons » Wed Apr 11, 2012 11:05 pm

Anything other than the o rings is part of the injector.
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Post by orangeneon05 » Thu Apr 12, 2012 2:27 am

ok even though they came off.....
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Post by occasional demons » Thu Apr 12, 2012 9:28 am

Got any way to post pics?
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Post by orangeneon05 » Fri Apr 13, 2012 4:21 am

yea i do i just wanted to see before i did it because im a tiny bit lazy...... hahah
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Post by occasional demons » Fri Apr 13, 2012 7:18 am

Just want to be sure we are on the same page. Hard to know exactly if we are thinking of the same thing. :)
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Post by INVUJerry » Fri Apr 13, 2012 7:21 am

If you buy a Felpro gasket for the rt intake manifold it includes the plenum gasket.
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Post by orangeneon05 » Fri Apr 13, 2012 11:39 am

INVUJerry wrote:If you buy a Felpro gasket for the rt intake manifold it includes the plenum gasket.
do you have a part number or a website to order it.
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